How To Laminate Wood To Create Thicker Wood Boards

Learn how to laminate wood and create thicker, stronger boards from thinner pieces. Our detailed guide covers everything from materials and tools to a step-by-step process for joining two pieces of wood lengthwise, offering practical tips for woodworking and DIY projects.

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Woodworking often presents challenges that require creativity and resourcefulness to overcome. One of those challenges is when you need thicker wood boards, but only have thinner boards available. Whether you’re working on a DIY furniture project, building cabinetry, or crafting custom pieces, the ability to create thicker wood boards by laminating thinner boards is an invaluable skill.

We’re avid DIYers and woodworkers who have now laminated our fair share of wood boards. We have laminated boards together to create 4×6 lumber for the frame of the popular Hanging Daybed project. We’ve also used it on a smaller scale to create the mosaic headboard panel for the daybed.

So with our experience, this comprehensive guide will walk you through the process of creating thicker wood boards using glue, the benefits of laminating wood, and the materials and tools you’ll need to succeed in your woodworking project.

What Does Laminating Wood Mean?

Laminating wood is a woodworking technique that involves bonding two or more thinner pieces of wood together to create a thicker, stronger, and often more stable piece of wood. This process is done using adhesive (most commonly wood glue) and applying pressure through clamps until the glue sets and hardens.

The Process of Laminating Wood

The key to laminating wood is ensuring that the pieces of wood are aligned and bonded correctly so that the final product is uniform and free from gaps or defects. Typically, the wood is glued edge to edge or face to face, depending on the desired outcome. The laminated boards are then clamped together to ensure even pressure across the bonding surfaces while the glue cures.

Once the glue dries, the result is a single, solid piece of wood that is stronger and thicker than the original individual boards. Laminated wood can be used in various applications, including furniture making, cabinetry, countertops, flooring, and even structural beams in construction.

Check out the FAQ at the end of this article for more details on types of wood lamination and how laminated wood differs from plywood.

Why Laminate Wood?

But why laminate wood instead of buying thicker stock? Here are some key reasons:

1. Cost Efficiency

Thinner boards are often more affordable than thicker ones. By laminating thin boards, you can achieve the thickness you need without the higher cost of a single thick board. This is particularly useful for hobbyists and DIYers working on a budget.

2. Material Availability

Sometimes, specific types of wood might not be available in the thickness you need, as was the case for our Hanging Daybed rebuild or for building legs for our DIY platform bed. For instance, exotic woods or reclaimed wood may only come in thinner sizes. Laminating allows you to use these beautiful or unique woods while achieving the necessary thickness.

3. Strength and Stability

Laminating multiple boards together can make the final product stronger and more resistant to warping, splitting, or twisting. This is because the grains of the wood can be alternated, creating a more balanced piece that doesn’t succumb to the natural tendencies of wood to move and change shape.

4. Aesthetic Opportunities

Laminating allows you to experiment with different types of wood for a unique visual effect. You can combine contrasting species, such as light and dark woods, to create interesting designs or accents within your board.

5. Custom Thickness

Sometimes, the required thickness for a project is non-standard, or perhaps you’re creating custom furniture where precise measurements are critical. Laminating thinner boards gives you complete control over the final dimensions of your material.

Laying out boards to decide the grain pattern and orientation.

Materials & Tools Needed

Before we dive into the step-by-step process, it’s essential to gather all the necessary materials and tools. Here’s what you’ll need:

Materials

Wood Glue – we prefer Titebond in bulk; get the correct type depending on interior vs exterior use.
Lots of Clamps
- Number and size of clamps will depend on length and total thickness of boards.
Desired Thinner Lumber – Choose your wood species based on your project requirements. Ensure the boards are straight and free of major defects.
Scrap Wood – Used as cauls to help distribute the clamping pressure evenly across the surface of the boards.

Tools

Table Saw or Circular Saw – To cut the wood boards to size before laminating. Can also be used to trim laminated boards and remove squeeze-out.
Orbital Sander and Sandpaper – To smooth out the surface after the glue-up. Various grits will be needed to smooth out the laminated board once it’s dry.
Measuring Tape and Square – Ensures accurate measurements and right angles.
Jointer or Hand Plane – To flatten the edges of the boards so they fit tightly together.
Brush or Roller (optional) – For applying the glue evenly. But you can use whatever you have to spread the glue.
Moisture Meter (optional) – Helps ensure that your wood isn’t too wet or too dry, which can affect glue adhesion and the stability of your laminated board.

Step-By-Step How To Create Thicker Wood Boards Using Glue

Now with your materials and tools ready, it’s time to get started. Follow this step-by-step guide to laminate thinner boards into a thicker, durable, and stable wood board.

Step 1: Preparing the Boards

Before gluing the boards together, it’s essential to prepare them so they fit seamlessly with each other. This step involves cutting the boards to the correct dimensions, jointing the edges, and ensuring they are flat and square.

Cut the Boards: Use a table saw or circular saw to cut the thinner boards to the desired length and width. Make sure to allow some extra material on each side for trimming later.
Check for Flatness: Lay the boards flat on a workbench to ensure they are straight. If any of the boards are slightly warped or cupped, you may need to plane them to ensure they will laminate properly.
Joint the Edges: If the edges of your boards aren’t perfectly straight, run them through a jointer or use a hand plane. This will ensure that the boards fit together tightly with no gaps.

Step 2: Dry Fit the Boards

Before applying any glue, do a dry fit to ensure everything lines up correctly. Lay the boards side by side in the order you plan to glue them. Check the grain direction, as alternating the grain can help improve stability. Make sure all the boards are flat and fit snugly together.

Step 3: Apply the Glue

Once you’re satisfied with the dry fit, it’s time to glue the boards together.

Prepare the Glue: PVA glue is commonly used and has an open time of around 10-20 minutes, which gives you some time to adjust the boards as needed. We recommend using Titebond’s glue as it comes in bulk in both interior and exterior ratings.
Apply the Glue: Using a brush or roller (or your hands like we do!), apply a generous and even layer of glue to the surfaces that will be joined. Make sure to cover the entire surface area to prevent gaps in the lamination.
Spread the Glue Evenly: It’s crucial that the glue is spread evenly across the entire surface. You don’t want too much glue, which can lead to heavy squeeze-out, but you also don’t want too little, which could result in weak bonding.

Step 4: Clamp the Boards

Once the glue is applied, you need to clamp the boards together while the glue dries.

Arrange the Clamps: Place the clamps evenly along the boards, ensuring even pressure across the length. Start by placing clamps underneath the boards, then add clamps on top, alternating their placement to balance the pressure.
Use Cauls to Distribute Pressure: Cauls are pieces of scrap wood that can be placed on the top and bottom of the boards, between the clamps and your project. This helps distribute the pressure from the clamps more evenly across the surface of the boards.
Tighten the Clamps: Gradually tighten the clamps, alternating between them to ensure even pressure. Be careful not to overtighten, as this can cause the boards to bow.
Check for Squeeze-Out: As you tighten the clamps, you should see some glue squeezing out from the joints. This is a good sign that you’ve applied enough glue and that the bond will be strong. You’ll be able to clean it up later.

Step 5: Let the Glue Dry

Patience is key here. Allow the glue to dry completely before removing the clamps. The drying time will vary depending on the type of glue you used and the temperature and humidity of your workspace. Most wood glues require at least 24 hours to cure fully, but you should always check the manufacturer’s recommendations.

Step 6: Trim and Sand the Laminated Wood Board

Once the glue is fully cured, it’s time to clean up the laminated board.

Remove Excess Glue: Before the glue hardens completely, you can use a chisel or scraper to remove excess glue from the joints. If the glue has already dried, sanding will also help remove any remaining residue.
Trim the Edges: Use a table saw or circular saw to trim the edges of the laminated board so they are flush and square.
Sand the Surface: Start with coarse-grit sandpaper to remove any high spots or imperfections, then gradually work your way up to a finer grit to smooth the surface. An orbital sander works well for this, but you can also sand by hand if needed.

Wood Lamination FAQ

How is laminated wood different from Plywood?

Laminating wood should not be confused with plywood, though the processes have some similarities. Plywood is created by layering thin sheets of wood veneer at alternating angles and gluing them together to form a panel. Laminated wood, on the other hand, typically involves taking solid boards and joining them together either along their edges (edge lamination) or faces (face lamination) to form a thicker piece.

While plywood is often used for its strength and resistance to warping due to its cross-grain construction, laminated wood is favored when a solid, natural wood appearance and custom thickness are desired. Laminating also offers more versatility in terms of combining different types of wood, making it a popular choice for aesthetic as well as functional purposes in DIY and woodworking projects.

What are the different types of wood laminations?

Laminating wood can take on various forms depending on the goals of the project:

Face Lamination: This involves bonding boards together along their faces to increase the thickness of the wood. For example, two 1 inch thick boards could be laminated together to create a 2 inch thick board.
Edge Lamination: This method is used when the boards are bonded along their edges, which is common in making wide panels, such as tabletops or cabinet doors. This is what we used for our mosaic headboard panel.
Cross Lamination: In this process, the boards are laminated at alternating angles, similar to plywood, to enhance strength and stability.

Face to Face wood lamination to create thicker lumber
Edge to Edge Wood Lamination to create a panel

More DIY Projects

Laminating wood is a practical solution when thicker wood stock is unavailable or when you want to create a specific aesthetic or structural quality in your project. It’s a technique that combines functionality with flexibility, making it a favorite among both DIY enthusiasts and woodworkers.

Check out more of our DIY projects articles for inspiration!

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Hope this step-by-step guide on how to laminate wood boards to create thicker lumber helped! Let us know what questions you have in the comments below!

Disclaimer: This post includes affiliate links, and I will earn a commission if you purchase through these links. Please note that I’ve linked to these products purely because I recommend them and they are from companies I trust. There is no additional cost to you.

How To Laminate Wood To Create Thicker Wood Boards